PV776-TSP142867

Service Manual Trucks Group 230–600

Fuel System D12, D12A, D12B, D12C

PV776-TSP142867

Foreword The descriptions and service procedures contained in this manual are based on designs and methods studies carried out up to August 2000. The products are under continuous development. Vehicles and components produced after the above date may therefore have different specifications and repair methods. When this is believ believed ed to have have a significant significant bearing on this manual, supplement supplementary ary service bulletins will be issued to cover the changes. The new edition of this manual will update the changes. In service procedures where the title incorporates an operation number, this is a reference to an S.R.T. (Standard Repair Time). Service procedures which do not include an operation number in the title are for general information and no reference is made to an S.R.T. The following levels of observations, cautions and warnings are used in this Service Documentation: Note: Indicates Note: Indicates a procedure, practice, or condition that must be followed in order to have the vehicle or component function in the manner intended. Caution: Indicates an unsafe practice where damage to the product could occur. Warning: Indicates Warning: Indicates an unsafe practice where personal injury or severe damage to the product could occur. Danger: Indicat Danger: Indicates es an unsafe unsafe practice practice where serious personal injury or death could occur.

Volvo Trucks North America, Inc. Greensboro, NC USA

Order number: PV776-TSP142867

© 2000 Volvo Volvo Trucks North America, Inc., Greensboro, NC USA

All rights reserved. No part of this publication may be reproduced, stored in retrieval system, or transmitted in any forms by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Volvo Trucks North America, Inc..

Contents General .................................................................................................... 3 Specifications ......................................................................................... 5 Fuel System ................................ ................. ............................... ............................... .............................. ............................ ............. 5 Fuel Supply Pump and Overfl Overflow Valve .......................... .......... ............................... ..................... ...... 5 Fuel Supply Pressure ............... .............................. .............................. ............................... ........................... ........... 5 Overfl Over flow Valve ........................................ ......................... ............................... ............................... ........................... ............ 5 Identifying Identifyi ng 450 kPa (65 psi) Fuel System Components ................ ................... ... 6 Tools ........................................................................................................ 7 Special Tools .............. .............................. ............................... ............................... ............................... ............................ ............. 7 Special Equipment .............................. ............... ............................... ............................... .............................. .................... ..... 9 Design and Function ........................................................................... 11 Fuel System ................................ ................. ............................... ............................... .............................. .......................... ........... 11 Fuel Line O-Rings ............... .............................. ............................... ............................... ............................... ................ 12 Unit Injectors ............... .............................. ............................... ............................... .............................. ........................ ......... 13 Injector Operation Operational al Phases ................ ............................... ............................... ............................. ............. 14 D12A .................................. ................... ............................... ............................... .............................. .............................. ............... 18 D12B .................................. ................... ............................... ............................... .............................. .............................. ............... 18 D12C ....................................... ........................ ............................... ............................... .............................. ......................... .......... 18 Fuel Flow ........................... ........... ............................... ............................... ............................... ............................... .................. .. 19 D12A .................................. ................... ............................... ............................... .............................. .............................. ............... 19 D12B .................................. ................... ............................... ............................... .............................. .............................. ............... 20 D12C ....................................... ........................ ............................... ............................... .............................. ......................... .......... 21 Fuel Filter ............... ............................... ............................... ............................... ............................... ............................ ............. 22 D12C ....................................... ........................ ............................... ............................... .............................. ......................... .......... 22 Overfl Over flow Valve ................................. .................. .............................. ............................... ............................... ................... .... 23 D12C ....................................... ........................ ............................... ............................... .............................. ......................... .......... 23 Fuel Feed Pump ................ . .............................. ............................... ............................... ............................... .................. .. 24 Fuel Feed Pump Replaceme Replacement nt ............... .............................. ............................... ......................... ......... 25 Hand Primer ................ . ............................... ............................... .............................. ............................... ...................... ...... 26 Engine Electronic Control Unit (EECU) ............... ............................... ............................... ................. 26 Troubleshooting ................................................................................... 27 Fuel System, Fault Tracing ............... .............................. ............................... ............................... .................... ..... 27 Fault Codes .............. .............................. ............................... ............................... ............................... .......................... ........... 27 Unit Injector Troubleshooti roubleshooting ng .............. .............................. ............................... .............................. .................. ... 27 Read and Document Fault Codes ............... .............................. .............................. ....................... ........ 27 Troubleshoo roubleshooting ting Flow Path ............... ............................... ............................... ............................... .................. .. 29 Active fault codes .............. ............................. ............................... ............................... ............................... ................ 29 Inactive fault fault codes with high counts .............. .............................. ............................... ................. 29 Unit Injector Mechanica Mechanicall Faults ............... .............................. ............................... ........................... ........... 32 1. Active code or misfi mis firing occur immediately immediately after start-up ......... ........... 32 2. Active code at normal operating operating temperature temperature and high idle ...... 32 3. Active code and misfi misfiring at BASE IDLE ONL ONLY Y ............... ......................... .......... 33 Locating Air in the Fuel System ............. ............................. ............................... ............................. .............. 34 Determining Whether There is Air in the Fuel ......... ................... .................... ............... ..... 35 Determining which Cylinder Cylinder is Introducing Air into the Fuel .......... ............. ... 41 Service Procedures ............................................................................. 43 General Work Practices ............... .............................. .............................. ............................... ......................... ......... 43 Clamping the Fuel Lines .............. ............................. .............................. ............................... ....................... ....... 44 Turning the Engine Over with the Star Starter ter Motor ............... .............................. ................. 44 Fuel System Pressure, Checking .............. ............................. .............................. ........................... ............ 45 Fuel System, Draining ................ ............................... .............................. ............................... ........................... ........... 47 1

Fuel System, Bleeding ............... .............................. ............................... ............................... .......................... ........... 50 Fuel Feed Pump, Replacemen Replacementt ............... ............................... ............................... ............................ ............. 52 D12, D12A, D12B ................... .... ............................... ............................... ............................... ............................ ............ 52 Fuel Feed Pump, Replacemen Replacementt ............... ............................... ............................... ............................ ............. 53 D12C ........................................ ........................ ............................... ............................... ............................... .......................... ........... 53 Types ................................ ................. ............................... ............................... .............................. ............................... .................. 54 Removal .................................. ................... ............................... ............................... .............................. ......................... .......... 54 Installation Installat ion ........................................... ............................ ............................... ............................... ............................ ............. 55 Hand-Primer Hand-Pr imer Pump, Replaceme Replacement nt ............... .............................. .............................. ........................ ......... 56 Fuel Filter, Replaceme Replacement nt .............. .............................. ............................... .............................. ........................ ......... 57 Overfl Over flow Valve, Checking ................ ............................... .............................. ............................... ...................... ...... 59 D12, D12A, D12B ................... .... ............................... ............................... ............................... ............................ ............ 59 Overfl Over flow Valve, Replaceme Replacement nt ..................... ...... ............................... ............................... ......................... .......... 60 D12, D12A, D12B ................... .... ............................... ............................... ............................... ............................ ............ 60 Overfl Over flow Valve, Replaceme Replacement nt ..................... ...... ............................... ............................... ......................... .......... 62 D12C ........................................ ........................ ............................... ............................... ............................... .......................... ........... 62 Unit Injector, Replacemen Replacementt (One) .............. .............................. ............................... .......................... ........... 63 Unit Injector, Adjustment .............. .............................. ............................... .............................. ........................ ......... 67 Unit Injector Copper Sleeve, Replaceme Replacement nt .............. .............................. ........................... ........... 69 Feedback Operation Numbers

2

Group 23 Fuel System, D12, D12A, D12B, D12C

General

General

W2003244

This information covers the fuel system of the Volvo D12 engine and includes engine versions D12, D12A, D12B, and D12C.

3

4


Specifications

Specifi Specifications Fuel System Component

Nm

ft-lb

Retainer bolt unit injector w/ NEW COPPER SLEEVE First tightening Step 1

20 ± 5

15 ± 4

First tightening Step 2

Turn an additional 180 ± 5 Loosen the retainer bolt for the unit injector prior to the second tightening.

Second tightening Step 1

20 ± 5

Second tightening Step 2

Turn an additional 60 ± 5

Component

15 ± 4

Nm

ft-lb

Retainer bolt unit injector w/ OLD COPPER SLEEVE Step 1

20 ± 5

Step 2

Turn an additional 60 ± 5

15 ± 4

Fuel Supply Pump and Overfl Overflow Valve Fuel Supply Pressure Engine Engine num number ber ...... ......... ..... ..... ..... ..... ..... ..... ...... ..... ..... ..... ..... ..... ..... ...... ..... ..... ..... ..... ..... ..... ...... ..... ..... ..... ..... ..... ..... ...... ..... ....

up to 987 98799 99

Minimum supply pressure at full load .................... .............................. ................... ................... ..........

250 kPa (36 psi)

from from 988 98800 00 350 kPa (51 psi)

Overfl Overflow Valve Engine Engine num number ber ...... ......... ..... ..... ..... ..... ..... ..... ...... ..... ..... ..... ..... ..... ..... ...... ..... ..... ..... ..... ..... ..... ...... ..... ..... ..... ..... ..... ..... ...... ..... ....

up to 987 98799 99

Opening pressure .................... .............................. .................... ................... ................... .................... .................... ..........

300-350 kPa (44-51 psi)

from from 988 98800 00 340-450 kPa (50-65 psi)

5


Specifications

Identifying 450 kPa (65 psi) Fuel System Components

W2003117

Fig. 1: Fuel System Components 1 2

350 kPa kPa (51 psi) psi) ove overrflow valve* New 450 kPa (65 psi) over overflow valve can be identifi identified by the groove cut into the hex portion of the valve as shown above.* 3 350 kPa (51 psi) fuel pump. pump. 4 New 450 kPa (65 psi) fuel pump can be be identi identifi fied by the additional web in the casting as shown above. (*D12A/B location shown.)

Important: When Important: When changing an overfl overflow valve to the new 450 kPa (65 psi) bar version, the fuel pump must also be changed to the 450 kPa (65 psi) version. However, when changing a fuel supply pump to the 450 kPa (65 psi) version, you are not required to change the overfl overflow valve.

W2003394

Fig. 2: Overfl Overflow valve location, D12C

6


Tools

Tools Special Tools The following special tools are used to replace or repair components. The tools can be ordered from Volvo Parts North America; please use the speci fied part number when ordering. Tools Tools with part numbers beginning with ” with ”J J” are available directly from KentMoore (telephone: 1 – 1 – 800 800 – 328 328 – 6657). 6657).

W0000404

9996390

Drift indicator extension for setting electronic unit injector

9996534

Gauge for checking fuel feed pressure

9996662

Pressure gauge

9996666

Union for checking fuel feed pressure

9996671

Fuel fi Fuel filter lter removal tool

9996956

Cranking tool for fl for flywheel ywheel

9998249

Protective sleeve sleeve for electronic unit injector

9998250

Sealing rings for the fuel gallery (2)

9998251

Sealing plug for cylinder head

9998277

Union for draining fuel system

9812546

Cleaning brush

J-41603 J-41196

Socket Dial indicator

7


Tools

W0001802

9998511

Lever tool

W2003530

9998599

Cleaning kit 1 2 3 4 5 6 7

W0001837

J-44515

Fuel vacuum tool

J-42885 –25 –25

Injector bore protecting sleeve

W2003529

8

9808 98086 614 — 14 — brush brush 9808 98086 615 — 15 — holder holder 9808 98086 613 — 13 — holder holder 9808 98086 616 — 16 — handle handle J-42 J-4288 885 5 – 25 — 25 — protecting protecting sleeve 9808 98086 617 — 17 — brush brush 9808 98086 618 — 18 — brush brush


Tools

Special Equipment Like the special tools, the following equipment will aid in servicing the D12 engine. When ordering equipment, specify the appropriate number.

W0001840

1159794

Torque wrench, 10 – 10 – 100 100 Nm (7 – (7 – 70 ft-lb)

W0000399

MT302A

SNAP-ON Remote Starter Cable Switch

9

10


Design and Function

Design and Function Fuel System

W2003243

Fig. 3: Fuel system, D12C The Volvo D12 is an electronic engine designed to meet today’ today’s high environmental standards. Meeting these standards requires optimum combustion. This demands, among other things, injecting the exact amount of fuel into the combustion chamber under very high pressure, at precisely the correct time, depending on engine speed, load, temperature and other conditions. Because totally mechanical injection systems cannot meet these demands, the engine is equipped with an electronically controlled injection system. An engine An engine electronic control unit (EECU) receives (EECU) receives impulses from the accelerator pedal and a number of sensors on the engine. The sensors read signals which govern the injection procedure and send these signals to the EECU. The fuel system has a built-in diagnostic system, which electronically detects and traces any faults in the system. Each cylinder has four valves. valves. Individual differences always occur between the cylinders in an internal combustion engine. The engine has a cylinder balancing system, the purpose of which is to even out the amounts of fuel between the cylinders. Cylinder balancing takes place with the engine running at idle speed, providing certain preconditions have been met.

11


Design and Function

Fuel Line O-Rings

W2002168

Fig. 4: Removing fuel lines Always replace the fuel line O-rings when:

• •

troubleshooting troubleshooting for for fuel aeration and/or performing any Service Procedure Procedure that requires the removal of VE D12 engine fuel lines.

W2002169

Fig. 5: Fuel line O-ring locations 1 2

12

976020 955984


Design and Function

Unit Injectors The fuel injection system of the D12 engine uses electronically-governed electronically-governed unit injectors that are electrically activated and mechanically driven via roller rocker arms from the camshaft lobe. They are vertically located in the center between the four valves in the cylinder head for each cylinder. cylinder. The electronic unit injector (EUI) combines an injection pump and an injector. An EUI can operate at considerably higher injection pressure than a conventional injector. The EUI consists of three main components:

•

Pump containing Pump containing a cylinder and piston; this corresponds to the pump assembly in an injection pump.

• •

Injector with Injector with nozzle body, body, nozzle needle and spring. Valve housing with housing with an electro-magnetically electro-magnetically controlled fuel valve. valve.

The upper part of the electronic unit injector, which includes the compression spring and valve housing, lies above the cylinder head. The center part of the electronic unit injector, where the intake and outlet holes for the fuel are located, lies in the cylinder head fuel gallery. The electronic unit injector takes in fuel directly from the fuel gallery. The lower part of the EUI is located in a copper sleeve against the bottom of the cylinder head, similar to a standard injector. injector. The EECU calculates injection timing and the amount of fuel to inject into the cylinder and transmits signals to the electromagnetically electromagnetically controlled fuel valve in the valve housing. The length of the injection time determines the amount of fuel injected into the cylinder.

T2006848

Fig. 6: Electronic unit injector (EUI) 1 2 3

Pump Pump part part Inje Inject ctor or part part Valve alve hou housin sing g

13


Design and Function

Injector Operational Phases Fill Phase During the fi the filling lling phase, the pump plunger (2) is on its way up, the camshaft lobe is passing its highest point, and the rocker arm is on its way toward the camshaft basic circle. The fuel valve (1) is open, allowing fuel to flow fl ow into the EUI from the lower fuel gallery (4). It flows fl ows into the cylinder head and the EUI pump cylinder. Filling continues until the pump plunger reaches its upper position.

T2006813

Fig. 7: Filling phase 1 2 3 4

14

Fuel Fuel valv valve e Pump Pump plun plunge gerr Fuel Fuel outlet outlet (over (overfl flow) Fuel gallery gallery (inlet (inlet and outlet) outlet)


Design and Function

Spill Phase The spill phase begins when the camshaft turns to the position at which the camshaft lobe forces the rocker arm to push the pump plunger (2) down. The fuel can now fl now flow ow through the fuel valve (1), through the holes in the EUI and out through the fuel gallery (4). The spill phase continues as long as the fuel valve (1) is open.

T2006814

Fig. 8: Spill phase 1 2 3 4

Fuel Fuel valve alve Pump Pump plun plunge gerr Fuel Fuel outlet outlet (over (overfl flow) Fuel gallery gallery (inlet (inlet and outlet) outlet)

15


Design and Function

Injection Phase The injection phase begins when the fuel valve (1) closes. The camshaft lobe and rocker arm continue to press down the pump plunger (2) and injection occurs as the route through the fuel valve closes. The injection phase continues as long as the fuel valve (1) is closed.

T2006815

Fig. 9: Injection phase 1 2 3 4

16

Fuel Fuel valv valve e Pump Pump plun plunge gerr Fuel Fuel outlet outlet (over (overfl flow) Fuel gallery gallery (inlet (inlet and outlet) outlet)


Design and Function

Pressure Drop Phase The injection phase ends when the fuel valve (1) opens and pressure in the EUI drops below the nozzle opening pressure. The fuel fl fuel flows ows through the open fuel valve (1), through the electronic unit injector holes and out through the fuel gallery (4). Note that the fuel valve position (closed or open) determines when the injection phase begins and ends. The time during which the fuel valve is closed determines the amount of fuel injected at each pump stroke. stroke.

T2006816

Fig. 10: Pressure drop phase 1 2 3 4

Fuel Fuel valve alve Pump Pump plun plunge gerr Fuel Fuel outlet outlet (over (overfl flow) Fuel gallery gallery (inlet (inlet and outlet) outlet)

17


Design and Function

D12A One unit injector is used for the 345, 385, and 425 horsepower variants. The spray angle has been modified. These injectors are NOT are NOT interchangeable interchangeable with the D12 injectors.

D12B The unit injectors on the D12B have a longer pump stroke length than earlier injectors on the D12A. They are not interchangeable with other engine versions. The engine electronic control unit (EECU) receives signals both from the engine’ engine’s own sensors and from the vehicle control unit. The EECU then controls the unit in jectors and determines the timing of the injection as well as the amount of fuel to be injected into the cylinders. With the adaptation to the new vehicle electronics, the throttle position sensor signal on the D12B is now linked to the engine control unit via the vehicle control unit.

CAUTION Using incorrect injectors (i.e. D12A injectors in a D12B engine) can cause engine damage and/or poor performance. performance. Injector identifi identification can only be made using the injector part number located on the injector solenoid valve.

D12C The D12C has new unit injectors, with 17 mm pump stroke and higher injection pressure. The injector nozzles are new, and have a different orifi ori fice pattern. Unlike the D12A and D12B engines, the D12C cylinder head only has one fuel galley for the unit injectors. This means that only two sealing rings are needed for each unit injector (the D12A and D12B use three rings). Fuel enters at the rear of the cylinder head and exits out the front.

T2012782

Fig. 11: Unit Injector, D12C

18


Design and Function

Fuel Flow D12A

W2000680

Fig. 12: Fuel fl Fuel flow, ow, D12A 1 2 3 4

Fuel Fuel feed feed pump pump Engine Engine electronic electronic control control unit (EECU) (EECU) Blee Bleed d line line Fuel Fuel gall gallery ery

5 6 7 8

Electronic Electronic unit injector injector (EUI) Overflow valve Fuel Fuel tank tank Fuel filter fi lter

The fuel feed pump (1) is mounted on the timing gear plate and driven through a recess in the pump shaft by the engine timing gears. It picks up fuel from the fuel tank (7) through the fuel system EECU (2). Return fuel from the cylinder head is also routed into the fuel feed pump. A bleed line (3) goes from the fuel feed pump back to the fuel tank, and is designed to continuously bleed the system. From the fuel feed pump, fuel fi fuel first rst passes through the fi the filter lter (8) and then into the cylinder head fuel gallery (4). The fuel gallery surrounds the part of the EUI (5) where the fuel holes are placed. The system overfl over flow valve (6) is located in the fuel gallery outlet connection. Leak-off fuel fl fuel flows ows from the EUI back to the fuel gallery, eliminating the need for an external fuel return.

19


Design and Function

D12B Unlike the D12A, the EECU on the D12B is fitted fitted with an external fuel cooling coil.

W2002628

Fig. 13: D12B, Fuel fl Fuel flow ow 1 2 3

Supp Supply ly pump pump EECU Blee Bleed d line line

4 5

Fuel Fuel gall gallery ery Unit Unit inje inject ctor or

The fuel system’ system’s supply pump (1) is attached to the timing gear plate and is driven via a groove in the pump shaft from the engine’ engine’s timing gears. The supply pump pulls fuel from the tank (7) through the EECU’ EECU’s cooling coil, which cools the EECU. The return fuel from the cylinder head is then blended with this fuel and enters the supply pump. From the supply pump (1), a bleed line (3) leads back to the fuel tank to provide continuous venting for the system. With the bleed line (3) as the only return line to the tank, the only fuel passing through the EECU’ EECU’s cooling coil is the amount consumed by the engine. From the supply pump (1), the fuel is forced through the fuel fi fuel filter lter (8) and then into the cylinder head fuel gallery (4). The fuel gallery is designed so that it surrounds that part of the unit injectors (5) where the fuel holes are located. The system’ system’s overfl overflow valve (6) is located in the fuel gallery’ gallery’s outlet connection. The overfl overflow valve regulates the fuel system’ system’s supply pressure. All fuel that exits the overfl overflow valve (leak-off fuel) is then blended with the fuel entering the supply pump.

20

6 7 8

Overflow valve Fuel Fuel tank tank Fuel filter fi lter


Design and Function

D12C

W2003243

Fig. 14: External fuel line installation and fuel flow, fl ow, D12C. 1

Bypass Bypass valv valve e

2

Fuel passage passage in cylinder cylinder head

The D12C uses a fuel line through the cylinder head. The bypass valve is also located toward the front of the cylinder head.

21


Design and Function

Fuel Filter The system is equipped with a large fuel filter fi lter located on the left-hand side of the engine. The filter fi lter insert consists of a special corrugated fi corrugated filter lter paper with a high resistance to water and very good filtering fi ltering properties. In addition, a fine-gauge net fi net filter lter on the fuel suction line in the fuel tank separates any possible solid impurities before the fuel is pumped up into the system.

T2006726

Fig. 15: Fuel fi Fuel filter lter 1 2

Drai Drain n nipp nipple le Blee Bleed d nipp nipple le

D12C The D12C uses a new fuel filter fi lter base, with hand pump mounted directly on the base. The base has a port for a fuel pressure sensor.

T2012783

Fig. 16: Fuel Filter, D12C

22


Design and Function

Overfl Overflow Valve The overfl overflow valve, located in the outlet from the cylinder head fuel gallery, regulates the fuel system feed pressure. Opening pressure is about 345 kPa (50 psi). The high feed pressure ensures that the injectors are fi are filled lled with fuel.

W2000681

Fig. 17: Overfl Overflow Valve Location, D12A/B

D12C The D12C has a new overfl overflow valve. The valve is integrated with the hollow screw in the fuel outlet at the front of the cylinder head.

T2012784

Fig. 18: Overfl Overflow Valve, D12C

W2003527

Fig. 19: Overfl Overflow Valve location, D12C

23


Design and Function

Fuel Feed Pump The capacity of the pump has been adapted to give the correct pressure and fl and flow ow to the EUI. Filling the EUIs requires relatively high pressure. The fl The flow ow must be large enough to even out any fuel temperature differences in the cylinder head fuel gallery.

T2006725

Fig. 20: Fuel Feed Pump

24


Design and Function

Fuel Feed Pump Replacement

W2002891

Fig. 21: A = Radial Play When replacing a D12 fuel supply pump for any reason, the accessory drive must also be inspected. There should be no radial or axial play in the accessory drive shaft. Radial play is movement parallel (side to side) to the face of the pulley. Do not confuse with backlash which is measured by turning the pulley. Axial play is movement perpendicular (in and out) to the face of the pulley. Release the tension on the alternator and fan belts before checking. This test is done by simply attempting to move the accessory drive pulley by hand.

CAUTION Radial or axial play in the accessory drive shaft may cause premature failure of the fuel feed pump.

25


Design and Function

Hand Primer The hand primer is situated on the fuel filter fi lter bracket. It is used to pump the fuel and bleed the system when the engine is not running.

T2006729

Fig. 22: Hand primer

Engine Electronic Control Unit (EECU) The electronic control module is the central part of the injection system. It is located on the left-hand side of the engine. The EECU receives continuous information from the accelerator pedal and from several sensors on the engine. It calculates the amount and the time to inject fuel into the cylinders. Electrical wiring to the EUI fuel valves transmits control signals to the injectors. The EECU uses the fl the flywheel ywheel sensor to monitor engine rotation and engine speed variations during a revolution. This allows the EECU to ensure that each EUI receives exactly the correct amount of fuel. The EECU stores information when a fault occurs or if something in the system is abnormal. Occassional faults are also stored and can be traced at a later stage. For information about the EECU, EECU, EECU sensors, and their functions, refer to: Service Information

280 – 600 600 Control Systems, D12

IMPACT

Function Group: 284 Information Type: Type: Design and Function ”Sensors” Sensors”

26


Troubleshooting

Troubleshooting Fuel System, Fault Tracing Correct fault diagnosis is essential to accurate engine repair. The complex design of the engine (that is, with a cylinder head that covers all the cylinders, overhead gear wheel-driven camshaft, and EUI) makes the cylinder head removal on the D12 a comprehensive work operation. Fault tracing in the fuel system requires thorough knowledge on how the system functions, as one does not have the opportunity as with a conventional conventional fuel system of seeing and checking directly on the engine. As the EECU receives all the information electronically from the different sensors, the EECU must gather all the information when the engine is started and then check that the information is correct. This means the D12 engine does not start on the first fi rst crankshaft revolution, but requires two revolutions revolutions in order for the control unit to set the correct values. It is important that the starter motor revolutions are not too slow, as slow starter motor speed is interpreted by the control unit that the crankshaft does not rotate and, as a result, the injector fuel valves do not receive the appropriate signals to release fuel. The crankshaft must rotate at a minimum of 75 rpm to ensure that the engine star ts. To To facilitate fault tracing in the fuel system, D12 is equipped with a diagnostic system which makes it possible to localize faults in the fuel system without having to perform extensive dismantling work. With the fault codes stored in the control unit, it is possible, through the diagnostic system, to quickly establish which fault or faults have occurred.

Fault Codes It is important to delete a fault code from the diagnostic system after the fault code has been corrected and beand before the truck leaves the workshop. Fault codes remain in the system until they are removed. They do not automatically clear when the fault has been corrected.

Unit Injector Troubleshooting roubleshooting The following information will aid in troubleshooting of Electronic Unit Injector (EUI) fault codes.

Read and Document Fault Codes Connect the MPSI tool to the vehicle’ vehicle’s diagnostic connector to determine whether any active or inactive fault codes are set. Document all set fault codes below:

27


Code #

Occurred counts

Active/Inactive

Troubleshooting

PID

SID

FMI

Description Descri ption ............................... ............... ............................... ............................... ............................... ............................... ............................... .............................. ............................... ............................... ............................. ..............

Code #

Occurred counts

Active/Inactive

PID

SID

FMI


Code #

Occurred counts

Active/Inactive

PID

SID

FMI


Code #

Occurred counts

Active/Inactive

PID

SID

FMI


28


Troubleshooting

Troubleshooting Flow Path Active fault codes Troubleshoot the active fault codes first. fi rst.

Inactive fault codes with high counts If inactive fault codes are recorded, follow the troubleshooting path for that same active code. This should be done; however, only when there is a driver complaint in conjunction with the inactive fault code.

Fault code 31, code 31, 32, 33, 34, 35 or 36

Active Electronic code

Refer to TSI Service Manual, Electronic Manual, Electronic Con- trol System, D12: "Fault "Fault codes 31-36: Electronic unit injectors." This will help you determine the supply and/or return pin for each code.

Remove the EA harness from the ECU, remove the white shield and inspect the terminals for damage (push back, tension, and/or corrosion). Use tool 9998482 to check tension, check ECU for pin damage. Is there damage?

Inactive Mechanical code

See “ See “Unit Unit Injector Mechanical Faults” Faults” page 32.

If inactive fault codes have been reported along with a driver complaint, follow the troubleshooting path for the active code. If the inactive code was not reported with a complaint, no further troubleshooting is necessary. Be sure to clear inactive codes.

NO

YES

Connect the J41132, 36-pin breakout box to the EA harness only. Check the EA harness and the injector solenoid for the correct resistance. To To determine the correct resistance value, subtract the resistance of the Digital Multimeter (DMM) from the total resistance of the injector solenoid circuit. Measure the resistance of the DMM by touching the leads together and noting the resistance.

Replace or repair the damaged terminals in EA harness. Use tool 9998482 to check tension. If the terminals are damaged in the EECU, other than slightly straightening, the EECU must be replaced.

Continued (see table (see table page 30). 30).

29


Troubleshooting

Continued from table from table page 29

Measure the circuit resistance between the injector supply and return pins into the EA harness and note the reading. Subtract the DMM lead resistance from the injector circuit resistance. This will give you the true circuit resistance. Compare to the specifi specifications below.

Note: Note: The ECU must NOT must NOT be be connected to the breakout harness during these checks. Specifi Specifications: * Solenoid circuit to ground ................... ............................. .................... .................... ................... ................... ..........

OL (open circuit)

* Solenoid circuit resistance ....................... ................................. .................... .................... ................... .............. .....

1.3-3.5

* Return circuit to block .................... ............................. ................... .................... .................... .................... ............... .....

OL (open circuit)

* Supply circuit to block .................... ............................. ................... .................... .................... .................... ............... .....

OL (open circuit)

Record the values.

Remove the valve cover, check the harness to solenoid connection. Is connection tight?

YES Remove the supply and return wiring from the injector solenoid and test the solenoid for open or short circuit to ground. Does the solenoid check within specifi specifications?

Tighten the connection, reassemble and check for active code.

YES

NO

The injector is good. Do not Do not replace replace the injector.

Replace the injector. injector.

Continued (see table (see table page 31) 31)

30

NO


Troubleshooting

Continued from table from table page 30

Continue to test the EA harness for open circuits, wiring shorted to ground, or shorted wire to wire in EA harness. Perform pull test during testing. Is the harness within specifi speci fications?

YE S Possible EECU failure. Contact Volvo with documented information before replacing the EECU. For VN, call 1-800-52-VOLVO. For VHD, call 1-887-97-VOLVO.

NO Repair or replace the EA harness.

Start the engine and check to be sure that the codes are inactive.

Clear the inactive fault codes.

31


Troubleshooting

Unit Injector Mechanical Faults Note: A Note: A mechanical fault indicates low performance of that cylinder, not just the injector. Determine the correct troubleshooting troubleshooting fl flow ow path. Fault codes: 31, 32, 33, 34, 35, 36.

1. Active code or misfi mis firing occur immediately after start-up Cause

Corrective action

•

Incorrect valve or injector injector adjustment adjustment

•

Check the valve and injector adjustment adjustment as required. required.

•

Injector problem

•

Perform Perform cylinder balancing balancing or manual manual compression test test before replacing the injector; refer to appropriate service literature or diagnostics checklists for information.

•

Base engine problem

•

Visual inspection inspection of the camshaft camshaft and high crankcase crankcase pressure. Perform Perform cylinder balancing or manual compression test before replacing the injector for piston and valve condition. Repair as required.

2. Active code at normal operating temperature and high idle Cause

Corrective action

•

Incorrect valve or injector adjustment adjustment

•

Check the valve and injector adjustment adjustment as required. required.

•

Poor quality fuel or excessive excessive fuel additives additives

•

Test with auxiliary auxiliary fuel and retest.

• Aeration

•

Check for for fuel restriction, restriction, air or compression introduced into the fuel system and repair as required.

•

Injector problem

•

Perform Perform cylinder balancing balancing test or manual comprescompression test. If within specifi specifications, replace injector. injector.

•

Base engine problem

•

Visual inspection inspection of camshaft and high crankcase pressure. Perform Perform cylinder balancing or manual compression test before replacing injector for piston and valve condition. Repair as required.

32


Troubleshooting

3. Active code and misfi mis firing at BASE IDLE ONLY Cause

•

Incorrect camshaft camshaft to crankshaft crankshaft static timing

Corrective action

•

Refer to Camshaft Timing procedure, procedure, Group 21.

If the answer to any of the following is yes, static timing may be the cause of the fault. •

Have previous previous repairs been been made to the engine that required removing removing the camshaft?

•

Can you clear the fault code, code, unplug the camshaft sensor, sensor, start the engine, and the fault code does not return?

•

Can you clear the fault fault code, start the engine, engine, set the idle above the base idle, idle, and the fault code code does not return?

33


Locating Air in the Fuel System Air in the fuel being supplied to the engine can cause a number of problems including hard starting, poor performance, and excessive smoke. Air can enter the fuel system at several several points:

• • • • • •

suction side fuel fuel supply lines pick-up in the the fuel fuel tank tank primary fuel fi fuel filter lter copper sleeve sleeve to injector injector seat injector tip fuel supply pump seals

Locating the point of entry can be troublesome and time consuming. A kit has been developed to aid in this process. The kit (J – 42753) 42753) consists of:

• • • • • • •

34

two fuel fuel line sight glass assemblies two transparent hose assemblies assemblies a clamp a washer a hollow screw copper gaskets O-rings

Troubleshooting


Troubleshooting

Determining Whether There is Air in the Fuel

Before working on a vehicle, set the parking brakes, place the transmission in neutral, and block the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death.

Do not service any part of the fuel system while smoking or in the presence of fl of flames, ames, sparks, or hot surfaces. surfaces. Failure to follow these precautions can result in fi in fire, re, which can cause serious injury or death.

WARNING HOT ENGINE! Keep yourself and your test equipment clear of all moving parts or hot engine parts and/or fluids. A hot engine and/or fl and/or fluids uids can cause burns or can permanently damage test equipment.

CAUTION After using the fuel aeration test kit, thoroughly drain all remaining fuel from the test hoses, then install plugs, end caps and washers. This will prevent accidental spillage which could result in fuel contamination.

35


Troubleshooting

W2003008

Fig. 23: D12, D12A Fuel System Diagram with Fuel Line Kit Installed 1 2 3 4 5

36

3/8 in. I.D. Transparent Suction Hose/Alternate Fuel Supply Sight Glass Hose Assembly Assembly (S) 3/16 in. I.D. I.D. Transparent ransparent Hose Sight Glass Hose Assembly Assembly (R) Vent Line Port Port Washer Washer (949873) (949873)


Troubleshooting

W2003009

Fig. 24: D12B Fuel System Diagram with Fuel Line Kit Installed 1 2 3 4

3/8 in. I.D. I.D. Transparent Suction Hose/Alternate Fuel Supply Sight Glass Hose Assembly Assembly (S) 3/16 in. I.D. I.D. Transpare ransparent nt Hose Sight Glass Hose Assembly Assembly (R)

37


Troubleshooting

W2003500

Fig. 25: D12C Fuel System Diagram with Fuel Line Kit Installed 1 2 3 4

38

3/8 in. I.D. Transparent Suction Hose/Alternate Fuel Supply Sight Glass Hose Assembly Assembly (S) 3/16 in. I.D. I.D. Transparent ransparent Hose Sight Glass Hose Assembly Assembly (R)


Note: The Note: The numbers within parentheses in the following steps correspond to the accompanying fi accompanying figures: gures: D12, D12A

See Fig. 23: D12, D12A Fuel System Diagram with Fuel Line Kit Installed, page 37

D12B

See Fig. 24: D12B Fuel System Diagram with Fuel Line Kit Installed, page 38

D12C

See Fig. 25: D12C Fuel System Diagram with Fuel Line Kit Installed, page 39

1 Connect the 3/16 in. I.D. I.D. transparent hose (3) to the bleed nipple located at the rear of the cylinder head and secure onto the bleed nipple with the clamp provided in the fuel line kit. Route the line back to the fuel tank and secure to prevent it from moving out of the tank. Open the bleed nipple 1 1/2 turns and pump the hand primer pump until the transparent hose is free of air. If the fuel system can be bled free of air continue to step 3. 2 If air continues to exist in the fuel, check the following: following:

• • • • •

that there there is ample fuel fuel in both tanks. connections from from the fuel tank tank to the fuel supply pump for suction leaks. fuel/water separator for restrictions, suction side leaks or an incorrect micron element. that the hand primer pump is capable of pumping fuel. the fuel supply supply pump seal for for failfailure.

3 Close the fuel bleed nipple and start the engine. Note: It Note: It may be necessary to continue to pump the hand primer during cranking to start the engine. If the engine does not start then the fuel system is most likely fi likely filling lling with air during cranking; skip to step 5.

Troubleshooting

4 Once the engine starts, open the fuel bleed nipple, located at the rear of the cylinder head, 1 1/2 turns with the transparent hose connected. Monitor for air in the fuel for 3 to 5 minutes. If air is present continue to step 5, if not then there is a possibility that air is entering the fuel system only under loaded conditions. If it is suspected that air is entering under loaded conditions continue to step 5. If not, stop here, no further testing is required. 5 If the engine would not start in step 3, continues aeration during cranking, or if air is noted in the transparent hose while the engine is running then install the following hoses and sight glasses to determine where the air is entering the fuel system. 6 Install sight glass hose assembly (2) between the outlet port of the fuel supply pump and the fuel filter. fi lter. 7 Remove the fuel supply (suction) line from the fuel supply pump and install the alternate transparent fuel supply line (1) and route back to the fuel tank. 8 Remove the two fuel lines at the overflow valve and install sight glass assembly (4) onto the overfl overflow valve using hollow screw (941686) from the kit, and route the line to the fuel tank. 9 Remove the Remove the transparent hose (3) from the bleed nipple at the rear of the cylinder head to the fuel tank and close the bleed nipple. Secure all three lines to prevent them from moving out of the fuel inside the tank. Note: For Note: For engines equipped with the small line located between the fuel supply pump and the top of the engine electronic control unit (EECU), this line must be disconnected from the fuel supply pump and the port from which the line was removed (5) must be plugged using two copper gaskets and washer (949873) supplied in the fuel line kit. 39


10 Using the hand primer pump attempt to purge all air from the fuel system and start the engine. Note: Purging Note: Purging time may vary. 11 Repeat the conditions in which aeration was previously noted or test under loaded conditions, i.e. dyno test. 12 Monitor the two sight glasses and transparent hose for aeration allowing 3 to 5 minutes for the sight glasses to clear. Note: Shining Note: Shining a fl a flashlight ashlight into the backside of backside of the sight glass will improve visibility. 13 If no air is noted in either sight glass and air was noted in previous steps, the air entry is most likely in the suction lines between the fuel supply pump and the fuel tank including the primary fuel fi fuel filter, lter, copper washers, Orings and pick-up inside of the fuel tanks. 14 If air is noted in sight glass (2) between the fuel supply pump and fuel filter, and the alternate fuel supply is supplying the fuel supply pump with a good fl good flow ow of air free fuel, the problem is most likely in the fuel pump seals. Note: The Note: The fuel in sight glass (2) is under pressure. This compresses the air bubbles and they will appear to be small.

40

Troubleshooting

15 If air is noted in the sight glass (4), at the rear of the cylinder head, but not in sight glass (2) at the outlet of the fuel supply pump (with no engine load), the problem is most likely within the cylinder head, i.e. copper sleeve to injector seat or injector tip leakage. See “Determining which Cylinder is Introducing Air into the Fuel” Fuel ” page 41. Note: Sight Note: Sight glass (4) will show small bubbles due to the turbulence created by the opening and closing of the overfl overflow valve. To determine whether normal or abnormal aeration is occurring, use the transparent hose (3) at the bleed nipple at the rear of the cylinder head. Open the bleed nipple 1 1/2 turns and monitor for air. If the line is clear then the aeration in the sight glass (4) is normal. If the transparent hose indicates aeration then the aeration in sight glass (4) is abnormal. 16 If air is noted only under loaded conditions, remove all six injectors and inspect the copper sleeve to the injector seat for signs of leakage.


Determining which Cylinder is Introducing Air into the Fuel




CAUTION After using the fuel aeration test kit, thoroughly drain all remaining fuel from the test hoses, then install plugs, end caps and washers. This will prevent accidental spillage which could result in fuel contamination.

Troubleshooting

Note: The Note: The numbers within parentheses in the following steps correspond to the accompanying fi accompanying figures: gures: D12, D12A

See Fig. 23: D12, D12A Fuel System Diagram with Fuel Line Kit Installed, page 37

D12B

See Fig. 24: D12B Fuel System Diagram with Fuel Line Kit Installed, page 38

D12C

See Fig. 25: D12C Fuel System Diagram with Fuel Line Kit Installed, page 39

1 Disconnect the two fuel lines from the overfl overflow valve at the rear of the cylinder head and install the sight glass (4) and line assembly onto the overfl overflow valve using hollow screw (941686), from the kit, and route into the fuel tank. Tie down the line to prevent it from moving out of the tank. 2 Remove the fuel supply line from the fuel supply pump and install the alternate fuel supply line onto the feed pump. Route the line back to the fuel tank. Tie down the line to prevent it from moving out of the fuel level inside the tank. Note: For Note: For engines equipped with the small line located between the fuel supply pump and the top of the engine electronic control unit (EECU), this line must be disconnected from the fuel supply pump. The port from which the line was removed (5) must be plugged using two copper gaskets and washer (949873) supplied in the fuel line kit. 3 Start the engine and allow 3 minutes for the sight glass to clear. Take Take note of the air present in the fuel sight glass (4). 4 Stop the engine and remove the valve cover.

41


5

Troubleshooting

7 Restart the engine and monitor the sight glass (4) in the rear of the cylinder head. If the air that was noted in step 3 is gone then the problem is most likely in the number 1 cylinder (injector tip or injector to copper sleeve seat). Remove the number 1 injector and inspect the injector to the copper sleeve seat. If the seat appears to be OK, replace the injector and perform the test again.

W2003027

Fig. 26: 1 base circle of camshaft Rotate the engine by hand until the rocker arm for the intake valve for number 1 cylinder is on the base circle of the cam, (in other words, in position to be adjusted). Turn the adjusting screw down (clockwise) until all clearance has been removed then turn it down an additional 1/4 turn (90 ). (90 ). Install the valve cover and secure with 4 nuts.

CAUTION Do not turn the adjusting screw down more than 1/4 turn (90 ) after all clearance has been removed. Engine damage will result.

6 Using the hand primer pump, purge all air from the fuel system.

CAUTION Run the engine only at idle speed with no load for this test. High engine speed or load could cause engine damage.

42

8 If the air that was noted in step 3 is not gone, stop the engine, remove the valve cover, cover, back out (counterclock(counterclockwise) the adjusting screw for the intake valve at the number 1 cylinder 1/2 round (180 ), and repeat the procedure (starting with step 5) on the number 2 cylinder. cylinder. 9 Continue the procedure until the cylinder that is introducing air into the fuel system has been determined. 10 When the cylinder that is introducing air into the fuel system has been located, remove that injector and inspect the injector to copper sleeve seat. If the seat appears to be O.K., replace the injector and perform the test again. If the seat and injector O-rings show signs of combustion leakage, clean the injector and replace the injector copper sleeve. Reinstall the injector with new O-rings and adjust all valves and injectors. 11 Start the engine and monitor the sight glass for air. If no air is present then stop. If air is present then test again as required.


Service Procedures

Service Procedures General Work Practices


The D12 engine uses high voltage (up to 90 V) to the electronic unit injectors. Do not come in contact with the injector terminals while the engine is running as there could be as much as 90V going to the electronic injectors. Contact may result in electrical shock. Personal injury or death can occur.

CAUTION Extreme cleanliness must be observed when working on the fuel system and the Volvo the Volvo Engine Brake (VEB). (VEB). Always clean the engine before beginning repairs. To To prevent dirt from entering the fuel system, install protective plugs whenever connections are removed. Store components in sealed plastic bags (when feasible) until they are to be reinstalled. The same procedures apply for VEB components. The oil channels for the VEB control system should also be plugged. Dirt in the fuel system and in the VEB system can affect engine operation. Note: After Note: After removing or replacing any EUI, or after ad justing preload, start the engine and allow it to reach normal operation temperature. Then let the engine idle for an additional fi additional five ve minutes. This will enable the ECM (through the cylinder-balancing system) to set the correct amount of fuel for delivery to the EUI. No powerconsuming components, for example, a PTO should be engaged. The exhaust pressure governor must not be activated. (Remove wire 636K from 636K from the solenoid valve and apply the parking brake to ensure that the truck cannot move.) When the engine runs evenly at idle speed, the cylinder-balancing function has been carried out.

•

Never remove remove the EECU connectors connectors or any any other electrical wires from the sensors while the engine is running. The ignition key must be in the OFF the OFF posi position and the engine stopped.

•

Never turn the battery master switch OFF switch OFF or or disconnect the battery cables while the engine is running.

•

When performing performing electric welding work on the truck, truck, the EECU connectors must be disconnected from the EECU. Note: Before Note: Before disconnecting the connectors, the key switch must be turned to the OFF the OFF position. position.

•

When oven-drying oven-drying spray-paint spray-paint work, any ECUs must be removed from the truck. The maximum allowable drying temperature, with the control unit in the vehicle, is 80 C (176 F).

•

Use only batteries for for auxiliary starting. Using a starting unit can induce peak voltages that can damage the electronic components.

•

When charging charging batteries with a rapid charger, charger, battery cables must be disconnected. (Normal trickle charging does not require this procedure.)

•

If a connector is removed, removed, make sure it is is reinstalled correctly and is not covered with oil or other fluids fl uids which can result in a poor connection.

•

For maintenance intervals, refer to: Service Bulletin

175-001 Oil and Filter Change Intervals

IMPACT

Function Group 175 Information Type: Maintenance Engine Maintenance

Note: If Note: If the engine is turned over with the starter motor (for example, when adjusting the valves) the fuse for the engine control system (B6) system (B6) must must fi first rst be removed and the ignition key must be in the OFF the OFF position position in order to eliminate any risk of the engine starting unintentionally. Also check that the gear lever is in neutral and the parking brake is applied.

43


Clamping the Fuel Lines

Service Procedures

Turning the Engine Over with the Starter Motor 1

Before working on a vehicle, set the parking brakes, place the transmission in neutral, and block the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death. Apply the parking brake, block the wheels, and place the gear lever in neutral. Make sure that the ignition key is in the OFF the OFF position. position. W2000684

Fig. 27: Fuel line routing and securing

2

To avoid damage and operational disturbances in the fuel system, the fuel lines should be rerouted and secured with plastic cable ties. Note: Always Note: Always check the fuel lines for cuts, abrasions, chafi chafing or leakage. Diesel fuel that comes in contact with a hot surface can start a fi a fire. re. Note: Refer Note: Refer to Service Bulletin, Group 23, for oil-cooler thermostat plate leak repair. repair. Note: Refer Note: Refer to Service Bulletin, Group 23, for accessory drive pulley information. Note: Refer Note: Refer to Service Bulletin, Group 23, for fuel line information.

W3000459

Fig. 28: EECU power supply relay, relay, D12A/B

W5001141

Fig. 29: R3 relay location (TEC Panel), D12C For D12/A/B only, disconnect the EECU power supply relay (1); for D12C (and later versions of D12B), disconnect the R3 relay (located in the TEC panel). 44


Service Procedures

2309-06-02-03 Fuel System Pressure, Checking

3

Note: Before Note: Before beginning this service procedure, please review “ review “General General Work Practices” Practices” page 43.


W3000458

Fig. 30: Remote starter switch and wiring Connect a switch between the battery positive (+) and the positive (+) connection on the starter solenoid.

Do not service any part of the fuel system while smoking or in the presence of flames, fl ames, sparks, or hot surfaces. surfaces. Failure to follow these precautions can result in fi in fire, re, which can cause serious injury or death.

WARNING 4 Do not run the starter for more than 15 seconds at any one time. However, However, if the starter is run for 15 seconds or longer, wait at least one minute before reusing the starter motor.

HOT ENGINE! Keep yourself and your test equipment clear of all moving parts or hot engine parts and/or fluids. A hot engine and/or fl and/or fluids uids can cause burns or can permanently damage test equipment.

WARNING Fuel, oil, or coolant leaked/spilled onto hot surfaces or electrical components can cause a fi a fire. re. Clean up spills immediately.

WARNING Do not work near the fan with the engine running or the ignition in the ON position. The engine fan can engage at any time without warning. Anyone near the fan when it turns on could be seriously injured.

Special tools: 9996666, 9998496, J–39200

45


1

Service Procedures

2

When operating a vehicle on streets and highways, during a data collection procedure, it is mandatory to have a second person drive while a technician collects the data. Monitor fuel pressure under full load, i.e, Dyno test or road test with load.

W2002209

Fig. 31: Bleed nipple, D12A/B

3 Compare measurements with specifi specifications found in “Fuel Supply Pump and Overfl Overflow Valve” Valve” page 5. Note: If Note: If measurements are found to be within specifi specifications, no further testing is required. However, However, if measurements do not meet specifi specifications, refer to the Diagnostics Checklist B, “Fuel System.” System.” .

W2003513

Fig. 32: Bleed nipple, D12C Remove the bleed nipple at the rear of the head on the D12A/B, or at the front of the head on the D12C; install adapter 9996666 and pressure transducer 9998496. Connect the transducer to multimeter J – 39200. 39200. Note: The Note: The pressure transducer measurement scale is in kPa.

46

9996666 9998496 J – 39200 39200


2309-11-03-01 Fuel System, Draining

Service Procedures

1





T2006719

Fig. 33: Draining the fuel system (D12A/B bleed nipple location shown) Carefully clean around the cylinder head bleed nipple and the fuel fi fuel filter lter bracket drain union located on the right side of the fi the filter lter housing.


2 Connect a 7.9 mm (5/16 in.) drain hose and open the fuel fi fuel filter lter bracket drain union. Remove the bleed nipple from the cylinder head.

WARNING Make sure that gauge pressure never exceeds 50 kPa (7.25 psi). Excessive pressure may cause personal in jury. jury. Note: Before Note: Before using, check the function of pressure gauge 6662 by attaching it to an air supply and setting the pressure to 50 kPa (7.25 psi) with the regulator valve.

Special tools: 9996662, 9998277

47


3

Service Procedures

4

T2006715

Fig. 34: Tool installation, D12A/B

T2006716

Check the pressure gauge assembly 1

Reduction valve

2

Air supply shut-off

Make sure the reduction valve knob is completely open (rotate counterclockwise). Open the shut-off tap. Connect pressure gauge 9996662 assembly to the shop air supply. supply.

W2003511

Fig. 35: Tool installation, D12C When the fuel has completely drained out of the cylinder head, install union 9998277 into the bleed nipple hole.

48

9998277

9996662


5

Service Procedures

6

T2006717

Fig. 36: Pressure gauge assembly connected to union, D12A/B

T2006718

Fig. 38: Draining the remainder of the fuel, D12A/B

Fig. 37: Pressure gauge assembly connected to union, D12C

Blow the remaining fuel out of the cylinder head by carefully increasing the pressure with the knob on the pressure gauge reduction valve. valve. DO NOT EXCEED 50 kPa (7.25 psi).

Check that the pressure gauge indicator is at “ at “0 0” (zero) and connect the gauge to union 9998277.

7 When all fuel has been drained:

W2003512

9998277

•

Remove Remove the pressure gauge gauge assembly, sembly, union and the drain hose.

•

Reinstall the b bleed leed nipple and the protective cap onto the cylinder head. Do not replace the nipple, as the original nipple is fitted fi tted to the seating in the cylinder head. A new nipple can result in leakage.

•

Tighten the drain drain union on the fuel fi fuel filter lter bracket and install the protective protective cap.

49


2309-05-03-01 Fuel System, Bleeding

Service Procedures

1



T2006713


Fig. 39: Cylinder head bleed nipple, D12A/B location

WARNING HOT ENGINE! Keep yourself yourself and your test equipment clear of all moving parts or hot engine parts and/or fluids. A hot engine and/or fl and/or fluids uids can cause burns or can permanently damage test equipment. W2003394

Fig. 40: Cylinder head bleed nipple, D12C location


T2006712

Fig. 41: Fuel fi Fuel filter lter bleed nipple Clean around the bleed nipples on the fuel fi fuel filter lter housing and cylinder head.

50


2

Service Procedures

4

T2006728

Fig. 42: Installing bleed line

T2006711

Fig. 43: Bleeding the cylinder head, D12A/B

Connect a transparent plastic hose to the fuel fi fuel filter lter housing bleed nipple. Open the bleed nipple and pump the hand primer until clean fuel runs out of the hose. Tighten the bleed nipple while fuel is still running out. 3 Remove the hose and install the protection plug on the bleed nipple.

W2003510

Fig. 44: Bleeding the cylinder head, D12C Move the hose over to the cylinderhead bleed nipple and bleed the system in the same way as with the fuel fi fuel filter lter housing. 5 Apply parking brake and place gear lever into neutral. 6 Start the engine and allow it to run at fast idle, or with the PTO engaged, for about fi about five ve minutes to remove air from the system. Check for leaks.

51


2331-03-02-01 Fuel Feed Pump, Replacement

Service Procedures

2

D12, D12A, D12B Note: Before Note: Before beginning this service procedure, please review “ review “General General Work Practices” Practices” page 43.



WARNING HOT ENGINE! Keep yourself yourself and your test equipment clear of all moving parts or hot engine parts and/or fluids. A hot engine and/or fl and/or fluids uids can cause burns or can permanently damage test equipment.

T2006724

Fig. 45: Removing fuel line Remove the plastic straps securing the fuel line on the ECM and cylinder block. Remove the lines at the unions from the fuel feed pump, as indicated by arrows in fi in figure gure Fig. 46: 46: Removi Removing ng fuel pump, page 52. 3



T2006723

Fig. 46: Removing fuel pump 1 Clean the area around the fuel feed pump area and remove the bleed line.

Remove Remove the bolts indicated by arrows in fi in figure gure Fig. 46: Removing fuel pump, page 52 and lift out the fuelfeed pump. 4 Clean the contact surface on the timing gear plate.

52


5

Service Procedures

9 Start the engine. Allow it to run at fast idle, or with the PTO engaged, for about fi about five ve minutes to remove air from the system. Check for leaks.

2331-03-02-01 Fuel Feed Pump, Replacement D12C Note: Before Note: Before beginning this service procedure, please review “ review “General General Work Practices” Practices” page 43.

T2006722

Fig. 47: Install fuel-feed pump


Check to make sure that the fuel-feed pump drive engages in the drive slot. Install a new gasket and tighten the fuel-feed pump mounting bolts. 6 Connect the fuel lines and the bleed line. Use new sealing washers. Secure the fuel lines with plastic tie straps.


7


WARNING T2006728

Fig. 48: Bleeding fuel system Bleed the fuel system at the fuel filter fi lter as shown in illustration, illustration, Fig. 48: 48: Bleeding fuel system, page 53. See also “Fuel System, Bleeding” Bleeding” page 50. 8 Apply parking brake and place gear lever into neutral.

Fuel, oil, or coolant leaked/spilled onto hot surfaces or electrical components can cause a fi a fire. re. Clean up spills immediately.


53


Service Procedures

Types CAUTION

There are two types of feed pump on the D12C engine: 1

When replacing feed pump Type pump Type 1, 1, great care must be taken with the long drive shaft. Any damage to the drive shaft can damage the feed pump; if it is installed on the engine, serious engine damage can result.

Removal 1

W2003386

Fig. 49: Feed pump, type 1 (older version, with long drive shaft). 1 2

Seal Shaf Shaftt journ journal al

2

W2003384

Cut the plastic clamps for the cabling and remove the bracket under the alternator. 2 Carefully clean round the feed pump and the fuel connections. W2003385

Fig. 50: Feed pump, type 2 (newer version, available available with one or two drive heads; available on newer and replacement engines). Feed pumps as spare parts are available in both versions. Note: Both Note: Both types of feed pumps are interchangeable, interchangeable, i.e. feed pump type 1 can be replaced with feed pump type 2 and vice versa.

3 Remove all fuel pipes from the feed pump. 4 Remove Remove the hold-down bolts for the feed pump. Carefully pull the drive shaft from the drive exhaust and remove the pump from the engine. 5 Clean the sealing surface on timing gears plate. Check that the gasket for the feed pump is in good condition. If necessary, necessary, replace with new gasket.

54


Service Procedures

Installation

3

1

W2003386

Fig. 51: Feed Pump Type 1 1 2

Seal Shaf Shaftt journ journal al

T2014660

Fig. 53: M8 – M8 – bolt bolt with sealant

(Feed Pump Type 1 only:) Check only:) Check that the seal (1) is in good condition and correctly positioned. Also check that the shaft journal (2) is lubricated with graphite grease.

Install the seal on the feed pump and install the feed pump on the engine.

CAUTION

2

(Feed Pump Type 2:) Observe great care with the feed pump’ pump’s drive shaft. Damage to the feed pump’ pump’s drive shaft can permanently damage the engine. Note. The Note. The M8 – M8 – bolt bolt should be reinstalled with sealant to seal any oil leakage. Do not Do not install install the old bolt without sealant or leakage can occur. 4 Check the seals on the fuel lines. The sealing washers for the return line should always be replaced. Replace other seals if necessary. necessary. Install the fuel lines on the feed pump.

W2003387

Fig. 52: Feed pump drive shaft groove Check that the feed pump’ pump’s drive installs in the groove on the feed pump’ pump ’s drive shaft. The groove in the shaft shows which position the feed pump’ pump’s shaft journal should have when installing ( applies to both type 1 and 2).

55


Service Procedures

2331-03-02-02 Hand-Primer Pump, Replacement

5



W2003388

Vent the fuel system. 6 Start the engine and run it at high revs (approx. 800 – 800 – 1000 1000 rpm) rpm) for approx. for approx. 10 min. to min. to evacuate any remaining air in the fuel system. 7 Conduct leakage check. 8 Check that no fault codes exist.

800 – 800 – 1000 1000 rpm approx. 10 min



WARNING Fuel, oil, or coolant leaked/spilled onto hot surfaces or electrical components can cause a fi a fire. re. Clean up spills immediately. 1 Open the fuel tank cap to release any pressure in the fuel tank. 2 Clean around the hand-primer fuel fit fi ttings.

56


Service Procedures

2334-03-02-01 Fuel Filter, Filter, Replacement

3

Prerequisite:

•

Container for fuel under fi under filter. lter.


Before working on a vehicle, set the parking brakes, place the transmission in neutral, and block the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death. T2006720

Fig. 54: Removing hand-primer pump Remove the hand-primer pump fuel lines at the unions. 4 Remove the hand-primer pump mounting bolts. 5 Install the new hand-primer pump using new sealing washers. 6 Reconnect the mounting bolts and fuel lines. 7 Bleed the fuel system (see “Fuel System, Bleeding” Bleeding” page 50). 8 Apply parking brake and place the gear lever into neutral. 9 Start the engine. Allow it to run at fast idle, or with the PTO engaged, for about fi about five ve minutes to remove air from the system and check for leaks.




Special tools: 9996671 1 Clean the area around the fuel fi fuel filter lter area.

57


Service Procedures

2

5

W2003389

Remove the fuel fi fuel filter. lter. 3 Clean the sealing surface, making sure that there is no residual gasket. 4 Install the new fuel fi fuel filter, lter, following the instructions on the fi the filter. lter.

CAUTION Do not fi not fillll the new fuel filter fi lter with fuel before installing. Doing so may allow foreign objects to get into the fuel, and can cause the injectors to malfuction.

W2003388

Bleed (vent) the fuel system at the fuel filter. Connect a transparent plastic hose to the bleed nipple. Open the bleed nipple and pump the hand primer until clean fuel runs out of the hose. Tighten the bleed nipple while fuel is still running out (see “Fuel System, Bleeding” Bleeding” page 50). 6 Remove the hose and reinstall the protection plug on the bleed nipple. 7 Apply parking brake and shift lever into neutral. 8 Start the engine. Allow it to run at fast idle, or with the PTO engaged, for about 10 minutes to evacuate any residual air in the fuel system.

58


2339-06-02-02 Overfl Overflow Valve, Checking

Service Procedures

1

D12, D12A, D12B Note: Before Note: Before beginning this service procedure, please review “ review “General General Work Practices” Practices” page 43.

Before working on a vehicle, set the parking brakes, place the transmission in neutral, and block the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death. W2002209

Fig. 55: Bleed nipple, D12A/B



W2003513

Fig. 56: Bleed nipple, D12C


Special tools: 9996666, 9998496, J – –39200 3 9200

Remove the bleed nipple at the rear of the head, install adapter 9996666 and pressure transducer 9998496. Connect the transducer to the multimeter J – 39200. 39200.

J – 39200 39200

Note: The Note: The pressure transducer measurement scale is in kPa. 2 Slowly pump the hand pump while monitoring the fuel pressure. The pressure should rise to a point determined by the opening of the overfl overflow valve then drop quickly. quickly. Recheck several times to get an accurate reading.

59


Service Procedures

3 The opening pressure should correspond to specifi specifications found in “ in “Fuel Fuel Supply Pump and Overfl Overflow Valve” Valve” page 5.

2339-03-02-02 Overfl Overflow Valve, Replacement

Note: If Note: If the overfl over flow valve opens at a pressure that is less than that given in the specifi specification, low fuel pressure will result. The valve must be replaced.


4 Replace the valve if necessary.

D12, D12A, D12B





60


1

Service Procedures

2

T2006730

Overfl Overflow valve

Carefully clean the area around the overfl overflow valve area.

T2006710

Draining fuel

Drain the fuel by connecting a hose to the fuel fi fuel filter lter housing drain nipple. Remove the protection plug and open the bleed nipple on the cylinder head. Route the fuel from the fuel fi fuel filter lter housing into a suitable container. 3

T2006714

Removing fuel lines

Remove the fuel line from the overfl over flow valve. 61


Service Procedures

4 Remove the overfl overflow valve.

2339-03-02-02 Overfl Overflow Valve, Replacement

5 Clean the contact surface on the cylinder head and install a new overfl overflow valve. valve. Use a new sealing washer. washer.

D12C

6 Reconnect the fuel line. Use new sealing washer. 7 Bleed the fuel system.



8 Apply parking brake and place the gear lever into neutral. 9 Start the engine and allow it to run at fast idle, or with the PTO engaged, for about ten minutes to remove air from the system. 10 Perform Perform leak and operation checks.



WARNING Fuel, oil, or coolant leaked/spilled onto hot surfaces or electrical components can cause a fi a fire. re. Clean up spills immediately. 1 Remove Remove the overfl overflow valve from the intake pipe. 2 Clean the sealing surfaces. surfaces.

62


Service Procedures

2371-03-02-02 Unit Injector, Injector, Replacement (One)

3

Not Included:

•

“Unit Injector, Adjustment” Adjustment” page 67


W2003390


Install a new overfl overflow valve with new copper washers and tighten the overflow valve to 55 ± 5 Nm (40 ± 4 ft-lb).




Special tools: 9998249, 9998511, 9998599, J – –44515 4 4515

63


Service Procedures

1

3

W2003391

Drain the fuel out of the system to prevent fuel running down into the cylinder when a unit injector is dismantled. T2009070

Prerequisites:

• • •

4

Valve cover removed. Control valve removed. Pipe removed removed between between control valve and rocker arm shaft.

2

T2008956

Remove Remove the injector hold-down bolt. 5 Clean very carefully round the unit in jector to be changed. T2008812

Release the rocker arm bridge as per the specifi specifications.

64


6

Service Procedures

9

W2003392

Remove the electrical cables from the unit injector and the bolt for the unit in jector’ jector’s attachment yoke. yoke. Remove the unit injector with tool 9998511.

9998511

W2003393

Fig. 58: Cleaning the copper sleeve Install cleaning sleeve 9998580 in the injector well and carefully clean the copper sleeve.

9998580 9998251

Leave cleaning sleeve 9998580 on the cylinder head until the dirt is removed from the injector well.

7

Note: If Note: If the unit injector is not installed immediately, immediately, install the protective plug 9998251 in the cylinder head. 10 Check the sealing rings on the unit in jector. jector. Install the unit injector and centre it between the valve springs. Tighten with a torque as per the specifications.

W0001837

Fig. 57: Vacuum pump J-44515 Remove fuel from the top of the piston using vacuum pump J-44515. 8 Install protective sleeve J – J – 42885 42885 – 25 25 on the unit injector.

J-44515

J – 42885 42885 – 25 25

65


11 Connect the electric cables to the in jector. jector. Note: Tighten Note: Tighten the nuts with a torque of 1.4 ± 0.1 Nm (3.5 ± 0.88 in-lb).

Service Procedures

14 1.4 ± 0.1 Nm (3.5 ± 0.88 inlb)

CAUTION Do not overtorque. This will break the stud. 12 Install the rocker arm bridge and tighten with a torque as per the specifications. 13

T2008812

Install the control valve. valve. 15 Connect the cables on the solenoid valve. Note: Tighten Note: Tighten the nuts with a torque of 1.4 ± 0.1 Nm (3.5 ± 0.88 in-lb).

1.4 ± 0.1 Nm (3.5 ± 0.88 inlb)

CAUTION Do not overtorque. This will break the stud.

T2009070

Install the pipe between the rocker arm shaft and control valve.

66

16 Adjust the valves. valves. 17 Install the valve cover and tighten according to the tightening schedule in the specifi specifications.


Service Procedures

2371-05-02-01 Unit Injector, Injector, Adjustment

18

(Adjusting pre-load) Note: Before Note: Before beginning this service procedure, please review “ review “General General Work Practices” Practices” page 43.

Before working on a vehicle, set the parking brakes, place the transmission in neutral, and block the wheels. Failure to do so can result in unexpected vehicle movement and can cause serious personal in jury or death. W2003388

Vent the fuel system at the fuel fi fuel filter. lter. 19 Do not service any part of the fuel system while smoking or in the presence of flames, fl ames, sparks, or hot surfaces. surfaces. Failure to follow these precautions can result in fi in fire, re, which can cause serious injury or death.


W2003394

Vent the fuel system on the cylinder head. 20 Start the engine and run for approx. 10 minutes to evacuate any residual air in the fuel system. 21 Check that the engine has reached normal working temperature and then run for another 5 minutes. 22 Check to make sure the fuel system is operating properly. properly. Check for leaks.

67



Service Procedures

2 Loosen the adjustment screw and ad just the unit injector rocker arm to zero clearance against the camshaft. Tighten the adjustment screw one full turn and then loosen again. Then return the rocker arm to zero clearance. 3


CAUTION Observe the greatest possible cleanliness when working on the cylinder head. Dirt particles in the fuel and oil channels can cause the unit injectors to malfunction, and can cause the VEB (if equipped) to fail.

Special tools: 9996956

T2008845

Preload the unit injector by screwing down the adjustment screw 3 screw 3 –4 –4 flats flats,, (180 (180 - 240 ). 240 ). Torque-tighten the lock nut according to the specifi specifications.

Unit Injector, Adjusting Pre-load 1

T2006935

Check that the camshaft line marking for adjusting the intake valves and unit injector are opposite the marking on the bearing cap, tolerance ± 2 mm (alternatively between the marks). Check, via the number marking on the camshaft on which cylinder unit injector pre-loading is to be adjusted. Important: If Important: If tool 6956 is used to crank the fl the flywheel, ywheel, make sure that the tool is removed if the engine is to be turned over with the starter motor.

68

3 –4 –4 flats flats (180 (180 - 240 ) 240 )


2379-03-02-02 Unit Injector Copper Sleeve, Replacement

Service Procedures

2


T2006777


Remove the rocker arm bridge bolts. Note: Loosen Note: Loosen the bolts in three equal stages to avoid bending the rocker arm shaft. 3

CAUTION




Failure Failure to remove the control valve before removing the rocker arm bridge may result in damage to the control valve and/or the pipe. If the engine is equipped with a VEB (Volvo (Volvo Engine Brake), remove remove the control valve and the pipe. Plug the ports and place the valve in a plastic bag to prevent it from being subjected to dirt and contamination. To facilitate removal, moval, remove the valve cover stud bolt. Note: On Note: On engines equipped with a VEB (Volvo (Volvo Engine Brake), secure the rocker arm plungers with rubber bands so that the plungers do not fall out of the rocker arms. 4


Removal 1 Connect a drain hose 9996049 to the engine coolant drain nipple and drain the coolant into a suitable container.

9996049

T2006776

Lift the rocker arm bridge using lifting tool 9998255.

9998255

69


5 Drain the fuel from the cylinder head. Refer to the procedure,“ procedure,“Fuel System Draining,” Draining,” the service manual 210 – 210 – 600, Basic Engine D12.

Service Procedures

8

6 Carefully clean around the electronic unit injector (EUI) to be removed. 7

T2006708

Remove the EUI and check that no dirt enters the injector well in the cylinder head. Install a dust cover on the EUI, and install protective plug 9998249 in the injector well in the cylinder head.

9998249

9

T2006709

Disconnect the electrical wires from the EUI.

CAUTION Pay close attention to the wire terminals. If one breaks, remove the broken pieces. Failure to do so may result in pieces falling into the cylinder, cylinder, which can cause component damage.

T2007050

Remove the valve bridges at the copper sleeve that is to be changed, and make note of location for reassembly. reassembly. 10 Make sure that the piston corresponding to the copper sleeve being removed is in the down position.

70


11

Service Procedures

13

W2003433

Using the Allen wrench, loosen the Allen set-screw on the extractor tool 9992853.

9998253

T2007157

(This step is for D12C only) Check only) Check whether the copper sleeve has an 8 mm or 9 mm hole in the tip. Install the 8 mm tap in tool 9998252 and try threading the copper sleeve. If it turns too easily, replace the 8 mm tap with the 9 mm tap and continue with the procedure. 12 Using tool 9998252 turn tap approximately 1/4 of a turn, then back off at least a full turn to remove shavings. Turn forward forward again until you feel tension, then repeat this step. Continue until the tap has passed through the bottom of the copper sleeve.

9998252 14 Adjust the bolt in the end of the tool until the bolt extends approximately 22 mm (0.875 in.) beyond the end of the tool(A).

9998252

15 Tighten the Allen set-screw and make sure that the screw is seated against the fl the flat at part of the extractor bolt.

Note: Apply Note: Apply grease to the tap to prevent shavings from falling down into the cylinder.

71


16

Service Procedures

18

W2003436

W2003434

Install the extractor tool into the copper sleeve and hand tighten until it bottoms out in the sleeve.

Hand turn the retaining nut clockwise (1) until it is firmly fi rmly seated against the bottom of the extracting cup.

19

17

W2003437

CAUTION W2003435

Back off the retaining nut (1) and turn the extractor bolt (2) so that the threaded end passes completely through the copper sleeve tip. Note: If Note: If the threaded end does not pass completely through the copper sleeve, the tip of the sleeve may break off as it is removed. 72

Do not use air tools to remove the copper sleeve. Use of air tools can damage engine components. Using a wrench, turn the retaining nut (1) clockwise until the copper sleeve is removed.


20

Service Procedures

22

W2003438

CAUTION Pieces of the copper sleeve that fall into the cylinder can seriously damage the piston and/or turbocharger.

T2006821

Install the 2 sealing clamps 9998250 in the cylinder head fuel gallery.

When the sleeve is removed, the extractor tool should be extended beyond the cooper sleeve at least 3 mm (0.125 in); see (1). If it is not, check to make sure that a piece of the cooper sleeve has not broken off and fallen into the cylinder. cylinder.

9998250

23

Cleaning the Copper Sleeve Bore 21

W2003148

WARNING Wear safety glasses while using cleaning brushes or compressed air. Failure to do so could cause eye in jury from flying fl ying debris. W2003537

Fig. 59: Cleaning kit J-42885 When replacing the injector copper sleeves in the cylinder head, it is important that the sleeve bore in the head is free from any carbon deposits and any other residue (i.e. pieces of the O-ring, etc.) before installing the new sleeve. Use the cleaning kit J42885 in the following steps.

J-42885

Use the “ the “7/16 7/16 in. diameter” diameter” brush inside bore (C). Move the brush up and down while turning it at the same time. J-42885

73


Service Procedures

Installation

24

1

W2003528

Place the injector bore sleeve protector into injector bore. Assemble the Roloc ® brush (2), the holder (3), and the extension (4). Install the assembly into a drill and clean the sleeve seal (B); see illustration page 73.

25 Install the 1.5 in. diameter brush into the drill and clean bore (A); see illustration page 73.

26 Use the chip vacuum PT-2900 to remove all debris from the copper sleeve bore.

J-42885

T2007088

J-42885

PT-2900 2

27 Inspect the copper sleeve bore for any remaining debris. Pay close attention to the O-ring area of the bore for any remaining pieces of the O-ring that may require scraping with a pocket knife to remove. Reclean if needed.

28 Remove the 2 sealing clamps 9998250 from the cylinder head fuel gallery, gallery, and remove remove any remaining debris using chip vacuum PT-2900.

Lubricate the new sealing ring with engine oil and install it on the new copper sleeve. Lubricate the sealing ring again with engine oil.

W2003176

9998250 PT-2900

Install the copper sleeve on the flaring fl aring tool 9998254, and lubricate the fl the flaring aring pin 9808000 with engine oil. Thread the fl the flaring aring tool 9998000 to the fl the flaring aring tool 9998254 until it bottoms. Then, loosen the fl the flaring aring pin approximately approximately 180 . Note: Failure Note: Failure to loosen the fl the flaring aring tool 180 can result in the pin being twisted twisted or broken. 3 Check that the piston is not at T.D.C. (if the piston is at T.D.C., the flywheel fl ywheel must be turned). Carefully tap down the copper sleeve until it bottoms out against the sleeve seal in the cylinder head.

4 Install and tighten the retainer for the electronic unit injector. injector. 74

9998254 9808000


5

Service Procedures

7

T2006707

T2007089

Flare the copper sleeve. Do this by turning the nut while counterholding the spindle until the flaring fl aring pin, 9998254 has been completely pulled through the copper sleeve.

9998254

8

Note: Failure Note: Failure to counterhold the spindle will result in a twisted or broken flaring pin. 6 Remove the fl the flaring aring tool 9998254 and pin 9808000.

Install the new sealing rings on the electronic unit injector (EUI). Lubricate the sealing rings with grease and install the electronic unit injector.

CAUTION

9998254 9808000

Remove all oil from the injector retainer bolt holes to prevent a hydraulic lock that may result in damage to the cylinder head. Tighten the electronic unit injector.

New Copper Sleeve: 9 Tighten retainer bolt to a torque of 20 ± 5 Nm (15 ± 4 ft-lb).

20 ± 5 Nm (15 ± 4 ft-lb)

75


10

Service Procedures

16

W2003181

Turn the retainer bolt an additional 180 ± 5 . 5 .

180 ± 5

T2006709

11 Loosen the retainer bolt for the unit in jector prior to the second tightening. 12 Tighten bolt to a torque of 20 ± 5 Nm (15 ± 4 ft-lb). 13 Turn the retainer bolt an additional 60 ± 5 . 5 .

20 ± 5 Nm (15 ± 4 ft-lb)

60 ± 5

Note: Be Note: Be careful not to pinch the EUI wiring cable harness when installing the valve cover.

Old Copper Sleeve: 14 Tighten the retainer bolt to a torque of 20 ± 5 Nm (15 ± 4 ft-lb).

20 ± 5 Nm (15 ± 4 ft-lb)

Note: If Note: If the injector is not to be installed at once, install a protective plug in the cylinder head. 15 Turn the retainer bolt an additional 60 ± 5 .

76

Connect the electronic unit injector (EUI) electrical wires and tighten the nut to a torque of 1.4 Nm (1 ft-lb). The EUI electrical wires should be routed to the outside of the valve cover bolts. Pay close attention to the cable holders. If one breaks, remove the broken pieces to prevent clogging or damage to any components.

60 ± 5

Note: Hold Note: Hold the wires while tightening. If the screw gets damaged, the complete electronic unit injector must be replaced. Note: Applies Note: Applies to engines equipped with VEB (Volvo (Volvo Engine Brake). The VEB control valve should be reinstalled at this time. Reconnect sliding valve and pipe into the rocker arm shaft as a unit. Apply Loctite ® 242 to threads and tighten the bolts to a torque of 33 ± 4 Nm (24 ± 3 ft-lb).

1.4 Nm (1 ft-lb) 33 ± 4 Nm (24 ± 3 ft-lb)


Service Procedures

17

19

T2006777

Install all rocker arm shaft bolts, making sure they are hand tight before continuing.

T2006820

Coat the valve bridges and camshaft lobes with engine oil.

Note: When Note: When reinstalling a rocker arm shaft which has been removed or loosened, only the bolts which hold the rocker arm shaft should be tightened.

18

T2006776

CAUTION Remove all oil from the rocker arm bridge bolt holes to prevent a hydraulic lock that may result in damage to the cylinder head. Install the rocker arm bridge, using lifting tool 9998255. 9998255

77


20

W2003520

Fig. 60: Bearing caps and camshaft/rocker shaft, tightening sequence D12C: 1 2 3 4 5

15 ± 5 Nm (11 ± 60 ± 5 Nm Nm (44 ± 15 ± 5 Nm (11 ± 60 ± 5 Nm (44 ± 0 Nm (0 ft-lb) 15 ± 5 Nm (11 ±

4 ft-l ft-lb); b); +90 ± 5 4 ft-lb) ft-lb) 4 ft-l ft-lb); b); +120 +120 ± 5 4 ft-l ft-lb); b); loosen loosen to 4 ft-l ft-lb); b); +120 +120 ± 5

D12, D12A, D12B: 1 2 3 4 5

15 ± 5 Nm (11 ± 4 ft-l ft-lb); b); +90 ± 5 45 Nm (33 (33 ft-lb ft-lb)) 15 ± 5 Nm (11 ± 4 ft-l ft-lb); b); +90 ± 5 45 Nm (33 ft-lb); ft-lb); loosen loosen to 0 Nm (0 ft-lb) 15 ± 5 Nm (11 ± 4 ft-l ft-lb); b); +90 ± 5

Gradually tighten the bolts so that the rocker arm shaft does not bend or warp. Tighten the shaft until it lies against the camshaft lobes, then torque tighten using the 5-step torque sequence shown. 21 Adjust the valves and the electronic unit injector (EUI).

78

Service Procedures

Feedback One of our objectives is that workshop personnel should have access to correct and appropriate service manuals where it concerns fault tracing, repairs and maintenance of Volvo trucks. In order to maintain the high standards of our literature, your opinions and experience when using this manual would be greatly appreciated. If you have any comments or suggestions, make a copy of this page, write down your comments and send them to us, either via telefax or mailing directly to the address listed below.

To

From

Volvo Trucks North America, Inc.

..........................................................................

Dept. 516 Service Publications

..........................................................................

7825 National Service Road

..........................................................................

P.O. Box 26115

..........................................................................

Greensboro, NC 27402-6115

..........................................................................

USA

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Comments/proposals ................................................................................................................................................................................ ................................................................................................................................................................................ ................................................................................................................................................................................ ................................................................................................................................................................................ ................................................................................................................................................................................ ................................................................................................................................................................................ ................................................................................................................................................................................ ................................................................................................................................................................................ ................................................................................................................................................................................ ................................................................................................................................................................................ ................................................................................................................................................................................ ................................................................................................................................................................................ ................................................................................................................................................................................ Concerns Service Manual:

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Operation Numbers 2309-05-03-01 2309309-06 06--02-0 02-03 3 2309-11-03-01 2331331-03 03--02-0 02-01 1 2331331-03 03--02-0 02-02 2 2334-03-02-01 2339-03-02-02 2339-06-02-02 2371371-03 03--02-0 02-02 2 2371-05-02-01 2379 2379-0 -033-02 02-0 -02 2

Fuel System, Bleeding . . . . . . . . . Fuel uel Syste ystem m Pressu essurre, Che Checking king . . . . Fuel System, Draining . . . . . . . . . . Fuel uel Feed Pum Pump, Repl Repla acem cement ent . . . . . Hand and-Pri -Prim mer Pum ump p, Repl eplacem aceme ent . . . . Fuel Filter, Replacement . . . . . . . . Overfl Overflow Valve, Replacement . . . . . . Overfl Overflow Valve, Checking . . . . . . . . Unit nit Inj Inject ector, or, Repla eplace cem ment ent (One) ne) . . . . Unit Injector, Adjustment . . . . . . . . Unit Unit Inje Inject ctor or Copp Copper er Slee Sleev ve, Repl Replac acem emen entt

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. . 50 . . 45 . . 47 52, 53 52, . . 56 . . 57 6 0, 0, 62 . . 59 . . 63 . . 67 . . 69

Volvo Trucks North America, Inc. P.O. Box 26115, Greensboro, NC 27402-6115

Volvo Trucks Canada, Ltd. 6490 Vipond Drive, Mississauga, Ontario L5T 1W8 http://www.volvotrucks.volvo.com

PV776-TSP142867 (1000) 08.200 © Volvo Trucks North America, Inc., 2000

PV776-TSP142867

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